|Publication number||US7560399 B2|
|Application number||US 10/960,402|
|Publication date||Jul 14, 2009|
|Filing date||Oct 7, 2004|
|Priority date||Aug 28, 1998|
|Also published as||DE09168849T1, DE602005017994D1, EP1645201A2, EP1645201A3, EP1645201B1, EP2116143A2, EP2116143A3, US20050075028|
|Publication number||10960402, 960402, US 7560399 B2, US 7560399B2, US-B2-7560399, US7560399 B2, US7560399B2|
|Inventors||Moshe Rock, Jane Hunter, Charles Haryslak, Gadalia Vainer|
|Original Assignee||Mmi-Ipco, Llc|
|Export Citation||BiBTeX, EndNote, RefMan|
|Patent Citations (104), Non-Patent Citations (16), Referenced by (14), Classifications (106), Legal Events (10)|
|External Links: USPTO, USPTO Assignment, Espacenet|
This application is a continuation-in-part of U.S. application Ser. No. 10/700,405, filed Nov. 4, 2003, now pending. This application is also a continuation-in-part of U.S. application Ser. No. 10/663,091, filed Sep. 15, 2003. The complete disclosures of both of these applications are incorporated herein by reference.
This invention relates to garments, and in particular to garments formed of multi-layer composite fabric.
Composite fabric articles are achieved by joining together one or more materials in a fabric body for the purpose of attaining desirable properties that cannot be attained by the fabric body or the individual materials alone. Laminated composites, e.g., those having multiple layers joined, e.g., by an adhesive, are sometimes formed for increasing thermal resistance performance of a composite fabric body.
Composite fabrics can be designed for wind and/or liquid water resistance. Composite fabrics of this type typically include a barrier membrane adhered to one fabric layer, or adhered or placed between fabric layers. The barrier membrane of such composite fabrics may be constructed to resist, or substantially impede, passage of air and wind through the fabric layers. However, this type of construction can make it difficult for water vapor to escape outwardly through the barrier, causing liquid to build up on the wearer's skin, with resulting discomfort, in particular during exercise or other physical exertion.
Other composite fabrics are designed to enhance water vapor permeability and airflow in order to improve comfort level for the wearer during physical activity. These fabrics, however, are typically poor insulators, and, as a result, during static physical conditions, i.e. when at or near rest, the wearer may experience discomfort due to flow of cool air through the fabric.
According to the invention, a composite fabric garment comprises a first garment portion disposed in one or more upper regions of the fabric garment, i.e. those regions relatively more likely in use to be exposed to wind and rain, and a second garment portion disposed in one or more lower regions of the fabric garment, i.e. those regions relatively less likely in use to be exposed to wind and rain. The first garment portion is formed of a first composite fabric comprising a first inner fabric layer, a first outer fabric layer, and a first intermediate barrier layer disposed between and bonded to at least one of the first inner fabric layer and the first outer fabric layer. The first intermediate barrier layer is breathable and substantially impermeable to wind and liquid water. The second garment portion is formed of a second composite fabric having predetermined air permeability and comprising, at least, a second inner fabric layer and a second outer fabric layer.
Preferred embodiments of the invention may include one or more of the following additional features. Lower regions of the fabric garment include a wearer's lower chest region and below. At least one of the first inner fabric layer and the second inner fabric layer comprises yarn with a plurality of synthetic fibers rendered hydrophilic. Preferably, the synthetic fibers of at least one of the first inner fabric layer and the second inner fabric layer rendered hydrophilic are selected from the group consisting of polyester and nylon. The first intermediate barrier layer comprises a first hydrophilic layer bonded to at least one of the first inner fabric layer and the first outer fabric layer by transfer coating from a carrier without a separate adhesive, the first intermediate barrier layer permitting moisture vapor transmission (MVT). Preferably, the first intermediate barrier layer further includes a second hydrophilic barrier layer disposed on and adhered to the other of the first inner fabric layer and the first outer fabric layer by transfer coating from a carrier without a separate adhesive, the first hydrophilic layer and the second hydrophilic layer being adhered together. More preferably, the first hydrophilic layer and the second hydrophilic layer are adhered together with adhesive. Preferably, the first hydrophilic layer is bonded to at least one of the first inner fabric layer and the first outer fabric layer by a discontinuous adhesive layer. The first inner fabric layer is hydrophilic. The first outer fabric layer is hydrophobic. At least one of the first inner fabric layer and the second inner fabric layer defines a surface comprising discrete pillar regions of relatively deeper pile, the discrete pillar regions of relatively deeper pile being spaced apart and isolated from each other by regions of relatively shorter pile or no pile that form a plurality of channels passing among the discrete pillar regions, the plurality of channels defining insulation regions to contain a cushion of air for promoting warmth under static conditions during periods of wearer inactivity and defining circulation regions creating avenues for flow of air and enhanced evaporation of moisture from the skin of the wearer for creating a heat dissipation or cooling effect during periods of physical activity by the wearer. Preferably, the plurality of channels formed along at least one of the first inner fabric layer and the second inner fabric layer comprises a plurality of intersecting vertical and horizontal channels. More preferably, the vertical channels formed along at least one of the first inner fabric layer and the second inner fabric layer are constructed by tipped and tipless sinkers, high and low sinkers, or a combination thereof. At least one of the first outer fabric layer and the second outer fabric layer comprises a knit construction of multi-filament, interlaced yarns with one or more outer surface regions having a non-continuous coating comprising discrete coating segments of coating material applied to bind individual yarn fibers together for enhanced resistance of the outer surface region to abrasion, pilling or fraying. At least one of the first inner fabric layer and the second inner fabric layer has a raised surface in a form selected from the group consisting of: velour, shearling, and loop terry. At least one of the first outer fabric layer and the second outer fabric layer has a construction selected from the group consisting of: woven construction, circular knit construction, single face knit construction, double face knit construction, and warp knit construction. Preferably, at least one of the first outer fabric layer and the second outer fabric layer has one-way stretch or two-way stretch. At least one of the first outer fabric layer and the second outer fabric layer has a raised surface and/or an unraised surface in one or more regions. In the upper portion of the composite fabric garment, at least the outer layer has a construction with minimal seams for improved resistance to penetration of water. The outer surface region of non-continuous coating is limited to one or more discrete regions of the outer surface and one or more other outer surface regions are substantially free of coating material. The outer surface region of non-continuous coating is limited to one or more discrete regions of the outer surface and one or more other outer surface regions have a continuous coating. The discrete regions and the other outer surface regions have contrasting resistance to abrasion and/or to pilling or fraying. The discrete regions and the other outer surface regions have contrasting air permeability. The discrete coating segments of coating materials comprise discrete dots. The coating material is selected from the group consisting of acrylic latex, polyurethane and silicone. The discrete regions correspond to regions of the garment typically subjected to relatively higher levels of abrasion and pilling or fraying during use. At least one of the first outer fabric layer and the second outer fabric layer comprises a fabric of knitted or woven construction of multi-filament, interlaced yarns with one or more outer surface regions having a non-continuous coating of binder material adhered to yarns and to yarn fibers at least at interlacing intersections for enhanced durability performance of the outer surface region against pilling or fraying during use. The multi-filament yarns comprise fibers formed of materials selected from the group consisting of polyester, nylon and polypropylene. Adhering of the binder material to yarn fibers is limited in a manner to substantially avoid restriction of air permeability through the composite fabric garment. The first inner fabric layer comprises a raised inner surface and a plain outer surface, the first inner fabric layer being formed of essentially hydrophobic material rendered hydrophilic to permit wicking of moisture from the raised inner surface to the plain outer surface, and wherein the first intermediate barrier layer comprises a first hydrophilic layer bonded to at least one of the first inner fabric layer and the first outer fabric layer, the first intermediate barrier layer permitting water vapor transport. The first intermediate barrier layer comprises a second hydrophilic layer disposed upon and adhered to the other of the first inner fabric layer and the first outer fabric layer, the first hydrophilic layer and the second hydrophilic layer being adhered together. The first intermediate barrier layer is essentially non-porous. The first intermediate barrier layer comprises hydrophilic polyurethane. The first outer fabric layer is hydrophobic. The first hydrophilic layer is bonded to at least one of the first inner fabric layer and the first outer fabric layer by a discontinuous adhesive layer. The first inner fabric layer comprises a raised inner surface and a plain outer surface, the first inner fabric layer being formed of essentially hydrophilic material to permit wicking of moisture from the raised inner surface to the plain outer surface, and wherein the first intermediate barrier layer comprises a non-porous hydrophilic layer, the first intermediate barrier layer permitting water vapor transport, and wherein a first hydrophilic adhesive layer affixes the first intermediate barrier layer to at least one of an outer surface of the first inner fabric layer and an inner surface of the first outer fabric layer. The first hydrophilic adhesive layer is continuous. The first hydrophilic adhesive layer affixes the first intermediate barrier layer to the outer surface of the first inner fabric layer, and a second hydrophilic adhesive layer affixes the first intermediate barrier layer to the inner surface of the first outer fabric layer. The second hydrophilic adhesive layer is continuous. The first intermediate barrier layer further comprises a second hydrophilic layer disposed upon and adhered to the first hydrophilic layer, the first hydrophilic layer being disposed upon and adhered to the first inner fabric layer, and the second hydrophilic layer being disposed upon and adhered to the first outer fabric layer, the first adhesive layer joining the first hydrophilic layer to the first inner fabric layer, and a second adhesive layer joining the second hydrophilic layer to the first outer fabric layer. The second adhesive layer is continuous. The first intermediate barrier layer is formed of essentially non-porous hydrophilic material. The second garment portion has a velour/velour construction selected from the group consisting of: woven construction, circular knit construction and warp knit construction, with predetermined air permeability, e.g. in the range of about 0 CFM to about 100 CFM, achieved in a non-laminate absent an intermediate barrier. The second garment portion further comprises a second intermediate, breathable, air-permeable barrier layer disposed between and bonded to at least one of the second inner fabric layer and second outer fabric layer. Preferably, the second intermediate, breathable, air-permeable barrier layer having predetermined air permeability, e.g. in the range of about 0 CFM to about 20 CFM, is selected from the group consisting of foamed adhesive in a discontinuous film, adhesive in a continuous film mechanically altered by a process of crushing and stretching, breathable adhesive in a discontinuous film, and wherein the predetermined air permeability of the second intermediate, breathable, air-permeable barrier layer is selected to allow air flow between the second inner fabric layer and the second outer fabric layer, and wherein the second intermediate, breathable, air-permeable barrier layer has a variable level of water vapor diffusion resistance that substantially decreases with increase in air speed of moving air impinging on the second composite fabric. The second intermediate, breathable, air-permeable barrier layer comprises an adhesive selected from the group consisting of an adhesive in the form of a mechanically altered breathable continuous film and a foamed breathable adhesive in the form of a discontinuous film. The second intermediate, breathable, air-permeable barrier comprises foamed adhesive in the form of a discontinuous film. The second intermediate, air-permeable vapor barrier comprises a breathable membrane disposed between the first fabric layer and the second fabric layer and adhered thereto with an adhesive. The breathable membrane is formed of a material selected from the group consisting of polyurethane, acrylic, polytetrafluoroethylene, polyester and combinations thereof. The breathable membrane comprises a membrane mechanically altered by a process of controlled stretching. The adhesive is selected from the group consisting of polyurethane, acrylic, polyarnide, polyester and combinations thereof.
The disclosures of the following applications are incorporated herein by reference: U.S. application Ser. No. 10/047,939; U.S. application Ser. No. 10/650,098; U.S. application Ser. No. 09/378,344; U.S. Provisional application No. 60/098,254; U.S. application Ser. No. 10/650,098; U.S. application Ser. No. 09/863,852; U.S. application Ser. No. 10/341,309; U.S. application Ser. No. 10/122,024; U.S. Application Ser. No. 09/982,720; U.S. application Ser. No. 09/883,643; and U.S. application Ser. No. 09/347,825.
The details of one or more embodiments of the invention are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the invention will be apparent from the description and drawings, and from the claims.
Like reference symbols in the various drawings indicate like elements.
In the embodiment of
In the embodiment of
Referring still to
As a result of the combinations of features of construction and materials described briefly above, and in more detail below, multi-layer composite fabric garments of the invention protect a wearer with a relatively high degree of resistance to penetration of liquid water and wind in areas of the garment that are relatively more likely to be exposed to rain and wind, while at the same time, the composite fabric garment also provides a relatively higher degree of water vapor permeability and controlled air flow in areas that are relatively less likely to be exposed to rain and wind. The multi-layer composite fabric garments of the invention thus provide a wearer with an increased overall level of comfort, e.g. as compared to prior art garments of similar design.
Features and advantages of multi-layer composite fabric garments of the invention will now be described in more detail.
Upper Portion of the Garments
Referring still to
During use, the inner fabric layer 115 of the upper portion 105 absorbs liquid moisture, e.g., sweat, which it then transports on a molecular level to and through the barrier layer 125 and through the outer fabric layer 120, to the outer surface, where the moisture evaporates.
The horizontal channels 130 of the inner surface 121 can be created in various different ways. For example, loop yarns can be removed from one or more of the feeds during knitting. As a result, yarn is excluded from preselected regions of the inner fabric layer 120 and channels 130 are created. As another example, a shrinkable loop yarn can be used in those areas where horizontal channels 130 are desired. Processing the fabric with wet heat (e.g., hot water or steam) or dry heat (e.g., hot air) causes the shrinkable yarn to shrink, creating channels 130. Vertical channels 135 can, for example, be formed by using tipped and tipless sinkers, high and low sinkers, or some combination of both. Other suitable methods are also contemplated.
The degree of thermal insulation and/or heat dissipation desired is a function of anticipated external conditions, e.g. of temperature and wind speed, and the expected level of physical exertion by the wearer. The level of thermal insulation and heat dissipation provided by the upper portion 105 of multi-layer composite fabric garments, in part, is a function of the cross-sectional flow area of the channels 130, 135. For example, as the cross-sectional area (e.g., the depth and/or width) of channels 130, 135 is increased, a greater volume of air can be contained within the channels. Thus, larger channels allow the upper portion 105 of garments 110, 100′ to provide a relatively higher level of thermal insulation and heat dissipation. Similarly, smaller channels in the upper portion 105 of the garments provide a relatively lower level of thermal insulation and heat dissipation.
The cross-sectional area of channels 130, 135 can be altered in various ways. For example, regions 126 of raised fibers defining channels 130, 135 can be napped or brushed such that regions 126 become further raised to cause channels 130, 135 to take on greater depth. Napping and/or brushing regions 126 also makes the inner surface 121 of inner fabric layer 120 softer to the touch and enhances moisture absorption. With respect to horizontal channels 130 in particular, the loop yarn may be removed from greater or fewer feeds and/or more or fewer loops of shrinkable yarn can be used to alter the cross-sectional area of the channels 130. Similarly, with respect to vertical channels 135, the sinker height can be increased or decreased to produce channels that are deeper or shallower, respectively. Other suitable techniques for altering the size of channels 130, 135 are also contemplated.
In some embodiments, inner fabric layer 120 is rendered hydrophilic to promote transport of moisture through the fabric. Thus, during use, liquid moisture, e.g., sweat, is transported through the hydrophilic inner fabric layer 120 by capillary action. As discussed above, inner fabric layer 120 may be configured to transport moisture away from the wearer's skin and toward the intermediate barrier 125. (The moisture is subsequently transported through the barrier to the outer fabric layer 115, where it is absorbed and/or spread towards the surface for evaporation, as described in more detail below.) This arrangement helps to resist build up of moisture on the wearer's skin, and thus further increases the comfort level of the wearer.
Various techniques can be used to render the inner fabric layer 120 hydrophilic. For example, inner fabric layer 120 may be chemically treated, e.g. as described in U.S. Pat. No. 5,312,667, the complete disclosure of which is incorporated herein by reference. In particular, a material such as low molecular weight polyester can be added to a dye bath used to dye the inner fabric layer 120.
Referring again to
In other embodiments, the outer fabric layer 115 alternatively may be formed of synthetic material, such as polyester, that has been rendered hydrophilic to help promote transport of moisture through the outer fabric layer 115. In these embodiments, liquid moisture is transported to the surface of the hydrophilic outer fabric layer 115 by capillary action after passing through barrier layer 125. Liquid moisture evaporates relatively rapidly from the surface of outer fabric layer 115, thus this arrangement increases the rate at which moisture is evaporated from outer layer 115, thereby increasing the rate at which moisture or sweat is removed from the region in contact with the wearer's skin.
In still other embodiments, the outer fabric layer 115 is formed from both moisture absorbent materials and materials that have been rendered hydrophilic. As a result, moisture is both absorbed by the outer fabric layer 115 and transported to the surface of outer fabric layer 115 by capillary action.
Still referring to
Breathability can be imparted to barrier layer 125 by forming the barrier layer to be sufficiently thin so as to permit water vapor to pass through the layer, as by an absorption-diffusion-desorption process in polyurethane barrier materials, or by providing material with micro-pores for the passage of water vapor. As described in U.S. Pat. Nos. 5,204,156, 5,268,212, and 5,364,678, the complete disclosures of all of which are incorporated herein by reference, barrier layer 125 may be formed of any of various water resistant materials. For example, barrier layer 125 may be formed from aromatic or aliphatic polyurethane. A suitable polyurethane material is available from UCB Chemical Corp., located in Drogenbos, Belgium. A micro-porous hydrophobic film, permeable to water vapor but impermeable to liquid water can also be used. Barrier layer 125 can be formed to be soft, with an ability to stretch and recover. In some cases, barrier layer 125 is formed of a material that adheres to fabric layers without application of an intervening adhesive layer.
Material used to form barrier layer 125 may also advantageously contain various useful additives. For example, the material may contain polyfunctional isocyanate to promote cross-linking, melamine to promote adhesion, aliphatic polyarnine to catalyze curing, and/or fluorocarbon resin to enhance water repellency.
A well-suited barrier can be formed from hydrophilic polyurethane derived from a solvent-based system, which permits moisture to pass through the barrier by an absorption-diffusion-desorption process. Such a polyurethane barrier is non-porous and formed so that body moisture will be transported therethrough, while being sufficiently resistant to passage of water droplets.
The thickness of barrier layer 125 is selected to balance its properties of liquid water resistance and vapor permeability. Typically, liquid water resistance of barrier layer 125 increases with thickness and vapor permeability of the barrier layer decreases with thickness. In some embodiments, the barrier layer 125 may be formed to be relatively thicker so as to increase liquid water resistance. In other embodiments, the barrier layer may be formed to be relatively thinner so as to increase its vapor permeability.
In addition, barrier layer 125 can be partially hydrophobic, in that there are fewer pores/mm2 than in a true hydrophobic barrier. Thus, moisture can pass through the hydrophilic portion of the barrier layer by an absorption-diffusion-desorption process and through micropores of the hydrophobic portion.
Various suitable techniques may be used to adhere the barrier layer 125 to the inner and/or outer fabric layers 120, 115. For example, still with reference to
In some embodiments, as described below, the barrier layer is adhered to the inner and outer fabric layers 120, 115 by an adhesive applied in a continuous or discontinuous layer. The adhesive may be hydrophilic or hydrophobic material. The barrier layer can also be adhered to the fabric layers 120, 115 by other methods, such as using heat or pressure.
Referring next to
Referring next to
The composite fabric of
Other multi-layer composite fabric constructions and arrangements using these and other material for creating in garments of the invention will also be apparent from the examples provided above.
Lower Portions of the Garments
As discussed above, the lower portions 110, 110′ of the multi-layer composite fabric garments 100 (shown in FIG. 1) and 100′ (shown in
Referring still to
The multi-layer composite fabric of the lower portions 110, 110′ can be constructed to provide a desired level of breathability. As indicated by the arrows in
In the absence of moving air, water vapor/moisture from the skin cannot be quickly transported through the fabric, which can lead to excessive build up of heat and moisture (sweat), in particular during strenuous exercise and/or warm conditions. When air is allowed to pass through the composite fabric, it facilitates more effective transfer of high moisture levels, and thus allows the wearer to be more comfortable.
As wind speed increases, more air flows through the barrier 170 or interface 175, allowing more water vapor to be dissipated. Thus, the lower portions 110, 110′ have relatively higher water vapor permeability in moving air and relatively lower water vapor permeability in static air. As a result, the lower portions 110, 110′ beneficially cool the wearer during periods of physical activity and warm the wearer during periods of inactivity.
The inner fabric layers 165, 165′ are similar to the inner fabric layer 120 of the upper portion 105, as described above with respect to
The inner fabric layers 165, 165′ can be treated or modified, e.g. as described in U.S. Pat. Nos. 5,204,156, 5,268,212, and 5,364,678. For example, inner fabric layers 165, 165′ can be rendered hydrophilic, provided with a raised surface, treated to be water repellant, etc.
In some embodiments, the outer fabric layers 160, 160′ are woven material, e.g. a two-way stretch woven material or a one-way stretch woven material, with one or more raised surface regions. In other embodiments, the outer fabric layers 160, 160′ are knit material, e.g. a one-way stretch knit material. The outer fabric layers may also be treated or modified, including as described in U.S. Pat. Nos. 5,204,156, 5,268,212, and 5,364,678. By way of example, the outer fabric layers 160, 160′ may be rendered hydrophilic, provided with a raised surface, treated to be water repellant, etc.
The barrier layer 170 of the multi-layer composite fabric of lower portion 110 can be of any material and/or configuration, e.g., as described in U.S. application Ser. No. 10/650,098, the complete disclosure of which is incorporated herein by reference. For example, referring again to
Membrane 270 can be formed from polyurethane, polytetrafluoroethylene or polyester. Adhesive layers 178, 180 can be applied to the membrane 270 by means of transfer coating from release paper at a thickness of between about 0.0001 inch and about 0.010 inch, or the adhesive layers can be applied directly onto the fabric surfaces at a thickness of between about 0.0003 inch and about 0.010 inch. The resulting composite fabric will have high moisture vapor transmission in both static conditions and in dynamic conditions, e.g. at about 10 CFM to about 100 CFM. In some preferred embodiments, the same or similar fabrics may be employed for the first inner layer and first outer layer of the upper portion of the composite fabric garment, with the first intermediate barrier layer of laminate film and adhesive constructed to permit a control degree of air permeability, e.g. at a selected level within the range of about 0 CFM to about 1.0 CFM, and the lower portion of the composite fabric garment can be constructed with little or no control, i.e. limit, on air permeability, permitting air flow in the range of about 0 CFM to about 100 CFM.
Referring now to FIG 10, a multi-layer composite fabric from which the lower portion 110 is constructed has an original width, W. The composite fabric is subjected to controlled stretching in such a manner as to result in a stretched width, W′. The composite fabric having the stretched width, W′, provides a relatively higher level of air permeability. More specifically, as the composite fabric is stretched, the interstitial spaces between the yarns become larger, with resulting increase in air permeability. Thus, the composite fabric can be stretched to a point of providing a desired level of air permeability.
Referring next to
Again, other multi-layer composite fabric constructions and arrangements using these and other material for creating in garments of the invention will also be apparent from the examples provided above.
Outer Surface Coating
One or more regions of the outer surface of the multi-layer composite fabric garments 100, 100′ may have a non-continuous protective coating applied thereon, e.g. for protection of the material surface from abrasion and pilling or fraying. For example, as described in application Ser. No. 10/700,405 and application Ser. No. 60/493,275, the complete disclosures of both of which are incorporated herein by reference, a non-continuous coating is adhered upon one or more selected regions of the relatively smooth outer surface of multi-layer composite fabric garments of the invention. The non-continuous outer surface coating enhances surface abrasion resistance and pilling resistance of the resulting fabric while allowing generation of controlled air permeability in a predetermined range to facilitate improved levels of moisture vapor transmission (MVT), which is particularly desirable for activities generating high metabolism rates.
Referring again to
In some embodiments, the outer fabric layers of the upper and lower portions 105, 110, 110′ of the garments 100, 100′ have one or multiple regions of non-continuous coating and one or multiple regions of continuous coating. The non-continuous coating is preferably applied to regions of the garments 100, 100′ subjected to relatively high perspiration levels during use, e.g., the underarm regions. The non-continuous coating, by being applied to those regions that are subjected to relatively higher perspiration levels, permits relatively higher levels of airflow, which facilitates moisture vapor transmission, while still enhancing the resistance to abrasion and pilling. The continuous coating permits the remaining regions of the garments 100, 100′ to be provided, e.g., with relatively higher abrasion and pilling resistances and relatively lower air permeability levels when desired. In some embodiments, the non-continuous coating may be applied or additionally applied in areas of the fabric article subjected to relatively high levels of wind impact (e.g., the chest of a shirt or jacket) to provide improved wind resistance due to the selected application of the coating material.
In addition to providing controlled air permeability, the coating material binds together yarn fibers to improve certain other structural and physical properties of the composite fabric. For example, the coating material, in binding together the individual fibers, forms bound fiber groupings (e.g., of at least about 5 fibers and up to about 100 fibers) and the tenacity of these groupings of fibers (e.g., from about 140 to about 350 grams per denier for a grouping of about 70 fibers) is greater than the tenacity of each individual fiber (e.g., from about 2 to about 5 grams per denier). Also, by coating and binding yarn fibers together within the first region 405, the abrasion and pilling resistances within the region of the composite fabric are improved. For example, pilling resistance within the coated regions of the composite fabric can be as high as five on a scale from one to five measured by ASTM D-3512. Face abrasion resistance of the composite fabric within the coated regions can be as high as five on a scale from one to five after 250 cycles measured by ASTM D-3884 and using a Martindale abrasion machine where the abrasion is done by a VELCRO® hook touch fastener tape mounted on the Martindale testing unit.
In binding together fibers of the yarn, the non-continuous coating 461 also provides greater freedom of yarn selection in the construction of the fabric. In some embodiments, the coating 461 facilitates use of relatively finer fibers (e.g., from about 5.0 dpf down to about 0.1 dpf) in the construction of the fabric, e.g., by reducing the risk of the fibers being pulled from the technical face. By utilizing relatively finer fibers, a tighter stitch can be achieved, which, in turn, improves the dynamic insulating performance of the resultant fabric by, e.g., providing relatively narrow air passageways through the fabric and increasing tortuosity through those passageways. In certain embodiments, the non-continuous coating 461, in binding fibers in the yarn of fabric 400, allows use of relatively weaker fibers, such as polyester and nylon, in construction of the fabric, which also provides greater tortuosity of air passageways to enhance dynamic insulation performance of the fabric.
A variety of coating materials can be used, including, e.g. acrylic (including acrylic latex), polyurethane and silicone. The coating can be selected to have a dry hand upon curing or drying, i.e. not tacky to the touch, good stretch/recovery, and good bond to textile fibers. The amount of coating material applied depends, at least in part, on the end use of the product. For example, in some cases, it may be desirable to greatly enhance the abrasion resistance of areas of the fabric. In these cases, relatively more coating material can be applied (e.g., more dots per square inch of fabric material and/or more material per dot). In other cases, it may be desirable for areas of the fabric article to have enhanced abrasion resistance, while having a relatively high level of air permeability. In these cases, relatively less coating material can be applied (e.g., less dots per square inch of material and/or less material per dot). The weight of the non-continuous coating 461 on the printed fabric can be between about 0.5 oz/yd3 to about 6.0 oz/yd3, and preferably is about 1.7 oz/yd3. The non-continuous coating 461 can be applied by any suitable method including, e.g., rotary printing, kiss rolling, and gravure rolling. In some cases, the non-continuous coating 461 is applied by a single head rotary screen having a selected number of holes per lineal inch (e.g., from about 30 holes per lineal inch to about 195 holes per lineal inch).
In some embodiments, coating or binder may be applied to yarns of the outer fabric surface of the garments 100, 100′ in different configurations. For example, referring to
Referring next to
In some embodiments, the binder or coating for forming a surface region of enhanced durability surface is applied to the outer surface of garments 100, 100′ with a pad. In order to reduce the tendency toward fraying while maintaining a high level of moisture vapor transmission, good drapability, hand and soft touch, deposit of the binder material is limited primarily to the fibers and/or to the intersections of fibers in the yarn segments, and formation of binder film in the interstitial spaces between yarns is minimized. The formation of film may particularly be avoided by removal of excess liquid binder from interstitial spaces between yarns shortly following application, e.g. while the binder material is still wet or moist, by air suction or air blowing through the fabric article.
The binder material can be applied in a low viscosity system, or in a system with relatively low level of binder solids or particulates in a liquid carrier, so that as the system dries, the liquid carrier evaporates (or in a foam system, collapses), leaving the solid binder deposited primarily or only on the yarns or yarn fibers. In this manner, the air permeability level and other characteristics of the base fabric are maintained.
In other embodiments, binder or coating material of relatively higher viscosity may be employed, to encourage formation of a fine film in interstitial areas between yarns that will partially or fully maintain its integrity during the drying process. In this manner, the fabric article may be provided with increased water repellency and wind resistance, which would be advantageous in cold windy ambient environments. However, a full or continuous film is typically to be avoided, in order to maintain at least a minimum desired degree of moisture vapor transmission necessary for comfort during high energy activities, such as running, skiing, etc.
The improved surface durability of multi-layer composite fabric articles of the invention is demonstrated in a severe pilling and abrasion test, such as the modified Martindale abrasion test method of ASTM D 4966. According to this test method, a fabric article of the invention to be tested is subjected to repeated rubbing by a strip of the hook element (General Application type, ¾-inch by ½-inch) of a hook-and-loop type fastener element. After 250 rubs, the appearance of the fabric article of the invention has been seen to be markedly better, e.g., as compared to untreated fabric articles.
A number of embodiments of the invention have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the invention. For example, in other embodiments, raised regions 126 of the inner surfaces of the upper portion 105 and lower portions 110, 110′ of garments of the invention can be formed to define channels of other, different arrangements, e.g., raised regions 126 may define horizontal channels alone, vertical channels alone, zig-zag channels, arcuate channels, or channels of any other desired shape or configuration capable of providing a cushion of air within the channels and/or permitting circulation of air through the channels. Accordingly, other embodiments are within the scope of the following claims.
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|U.S. Classification||442/76, 428/91, 2/97, 442/85, 2/87, 2/69, 442/86, 2/82|
|International Classification||A41D31/00, B32B5/26, A41D27/04, D06C11/00, B32B5/18, A41D3/00, A41D31/02, D06N7/00, D04B21/14, B32B27/04, D04B1/24, A41D13/00, D04B1/04, D04B1/14, A41D1/00, A41D3/04|
|Cooperative Classification||Y10T442/2221, Y10T442/30, Y10T442/3358, Y10T442/3504, Y10T442/3512, Y10T442/3472, Y10T442/40, Y10T442/3366, Y10T442/425, Y10T442/3301, Y10T442/335, Y10T442/413, Y10T428/2395, Y10T442/488, Y10T442/3317, Y10T442/2139, Y10T442/2213, D06N2209/142, D06N2209/123, D06N2209/141, B32B5/26, A41D31/02, B32B5/026, B32B5/024, B32B37/1284, B32B27/34, B32B27/308, B32B27/40, B32B7/12, D04B1/14, A41D13/00, B32B7/045, B32B2459/00, B32B2307/726, A41D3/005, B32B2307/724, D10B2331/021, B32B2262/0276, A41D2400/422, D04B1/04, D10B2401/022, B32B2262/0261, B32B27/08, A41D2400/20, B32B2038/0028, D04B1/24, Y10T428/24636, A41D31/0038, B32B2307/304, A41D31/0027, B32B2307/73, B32B2307/7265, B32B2250/40, A41D27/04, A41D2400/22, B32B2307/728, B32B2437/00, D04B21/14, B32B27/12, B32B2307/712|
|European Classification||A41D3/00P, B32B27/08, B32B27/34, B32B5/02B, B32B5/02C, B32B7/12, B32B27/40, B32B7/04A, B32B27/12, B32B27/30D, D06N7/00, A41D31/02, B32B37/12D, A41D27/04, D04B1/04, B32B5/26, A41D31/00C4L, D04B21/14, A41D31/00C6L, A41D13/00, D04B1/14, D04B1/24|
|Dec 7, 2004||AS||Assignment|
Owner name: MALDEN MILLS INDUSTRIES, INC., MASSACHUSETTS
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNORS:ROCK, MOSHE;HUNTER, JANE;HARYSLAK, CHARLES;AND OTHERS;REEL/FRAME:015432/0643;SIGNING DATES FROM 20041020 TO 20041022
|Apr 2, 2007||AS||Assignment|
Owner name: MMI-IPCO, LLC, MASSACHUSETTS
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